Sun visor assembly including an add-on sun visor

ABSTRACT

A sun visor assembly includes a sun visor panel. A first arm extends from the sun visor panel. An attachment assembly is supported by the first arm. The first arm is rotatably coupled with the attachment assembly. The attachment assembly is configured to detachably connect with a second arm of a second sun visor panel. The attachment assembly includes a connection block. The connection block includes an orifice. A connection arm includes a projection at a first end of the connection arm. The projection is configured to releasably connect with the orifice of the connection block. A connection loop extends from a second end of the connection arm. The connection loop is configured to connect with the second arm of the second sun visor panel.

CROSS-REFERENCE TO RELATED APPLICATION

This U.S. Non-Provisional Patent application claims priority to U.S.Provisional Patent Application No. 63/104,562, filed on Oct. 23, 2020,the disclosure of which is incorporated by reference in its entirety.

FIELD

The present disclosure relates to a sun visor assembly, and moreparticularly, to a sun visor assembly including an add-on sun visorsuitable as an aftermarket product for a motorized vehicle such as acar, truck, or van.

BACKGROUND

Generally, factory provided sun visors in vehicles provide only one offront or side sun protection for a vehicle operator. For example, afactory provided sun visor may be adjusted to provide shade in a sidewindow, but not the front windshield. However, vehicles traveling at anangle to the sun, or on a curved road may need to frequently adjust thefactory provided sun visor from the front-facing or side-facing positionto account for various angles of the vehicle with respect to the sun.

SUMMARY

Provided in accordance with aspects of the present disclosure is a sunvisor assembly including a sun visor panel. A first arm extends from thesun visor panel. An attachment assembly is supported by the first arm.The first arm is rotatably coupled with the attachment assembly. Theattachment assembly is configured to detachably connect with a secondarm of a second sun visor panel. The attachment assembly includes aconnection block. The connection block includes an orifice. A connectionarm includes a projection at a first end of the connection arm. Theprojection is configured to releasably connect with the orifice of theconnection block. A connection loop extends from a second end of theconnection arm. The connection loop is configured to connect with thesecond arm of the second sun visor panel.

In an aspect of the present disclosure, the projection of the connectionarm releasably connects with the orifice of the connection block by asnap-fit connection.

In an aspect of the present disclosure, the projection of the connectionarm is an annular cantilever snap joint. The orifice of the connectionblock is shaped and dimensioned to receive the annular cantilever snapjoint.

In an aspect of the present disclosure, the projection of the connectionarm is a discontinuous annular cantilever snap joint. The orifice of theconnection block is shaped and dimensioned to receive the discontinuousannular cantilever snap joint.

In an aspect of the present disclosure, the projection of the connectionarm is shaped as a ball. The orifice of the connection block is socketshaped and dimensioned to releasably receive the ball.

In an aspect of the present disclosure, the first arm has a bent shapeincluding a horizontal extending portion and a vertical extendingportion. The connection block is supported by the vertical extendingportion.

In an aspect of the present disclosure, the sun visor panel ishorizontally translatable along the horizontal extending portion of thefirst arm. The horizontal extending portion of the first arm includes anextension portion configured to allow horizontal translation of the sunvisor panel. The extension portion is at least partially positionedbetween a front surface and a rear surface of the sun visor panel.

In an aspect of the present disclosure, an extension panel is slidablyextendable from a distal end of the sun visor panel to extend a lengthof the sun visor panel.

In an aspect of the present disclosure, a hinge connects the extensionpanel to a distal end of the sun visor panel. The hinge is configured toallow the extension panel to fold away from the sun visor panel toextend a length of the sun visor panel. The hinge may be a butt hinge, amortise hinge, a continuous hinge, or a piano hinge.

In an aspect of the present disclosure, the connection loop is anadjustable ring configured to be circumferentially coupled about thesecond arm of the second sun visor panel. The adjustable ring includes arubber ring configured to directly contact the second arm of the secondsun visor panel. An adjustable metal ring is positioned around therubber ring. The adjustable metal ring is configured to be tightenedaround the rubber ring to secure the adjustable ring to the second armof the second sun visor panel.

In an aspect of the present disclosure, the sun visor panel includes aninner layer including plastic or a polymer, and an outer layer includinga fabric material covering the inner layer.

In an aspect of the present disclosure, the first arm includes metal.

In an aspect of the present disclosure, the connection arm and theprojection are a single integrally formed structure.

In an aspect of the present disclosure, the connection block includes aplastic material or a polymer material.

In an aspect of the present disclosure, the second end of the connectionarm is narrower in at least one direction than the first end of theconnection arm.

In an aspect of the present disclosure, a magnet is supported on the sunvisor panel. The magnet is configured to magnetically secure the sunvisor panel to an upper surface of a vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects and features of the present disclosure are describedhereinbelow with reference to the drawings wherein:

FIG. 1 is a rear view of a sun visor assembly according to aspects ofthe present disclosure;

FIG. 2A is a rear view of the sun visor assembly with a connection armreleasably connected with a connection block;

FIG. 2B is a rear view of the sun visor assembly with the connection armdisconnected from the connection block;

FIG. 3A is a rear view of the sun visor assembly including a slidingextension panel of the sun visor panel in a retracted configuration;

FIG. 3B is a rear view of the sun visor assembly with the slidingextension panel in an extended configuration;

FIG. 4A is a rear view of the sun visor assembly including a foldingextension panel of the sun visor panel in a collapsed configuration;

FIG. 4B is a rear view of the sun visor assembly including the foldingextension panel of the sun visor panel in a deployed configuration;

FIG. 5A is a rear view of a horizontally translatable sun visor panel ina first horizontal position;

FIG. 5B is a rear view of the horizontally translatable sun visor panelin a second horizontal position that is aligned with a second sun visorpanel;

FIG. 6 illustrates an exemplary cantilever snap joint configured toreleasably connect the connection arm with the connection block;

FIG. 7 illustrates an exemplary ball and socket joint configured toreleasably connect the connection arm with the connection block;

FIG. 8 illustrates an exemplary connection loop configured to becircumferentially coupled about a second arm of a second sun visorpanel;

FIG. 9 illustrates an exemplary connection loop coupled to a second armof a second sun visor panel;

FIG. 10 is an interior view of a sun visor panel according to aspects ofthe present disclosure;

FIG. 11 is a front, perspective view of a sun visor assembly accordingto aspects of the present disclosure;

FIG. 12 is an enlarged, perspective view of the attachment assembly ofFIG. 11;

FIG. 13 is rear view of the sun visor panel of FIG. 11; and

FIG. 14 is an enlarged view of area A of FIG. 13.

DETAILED DESCRIPTION

The terms “about,” substantially,” and the like, as utilized herein, aremeant to account for manufacturing, material, environmental, use, and/ormeasurement tolerances and variations, and in any event may encompassdifferences of up to 10%. Further, to the extent consistent, any of theaspects described herein may be used in conjunction with any or all ofthe other aspects described herein.

Descriptions of technical features or aspects of an exemplaryconfiguration of the disclosure should typically be considered asavailable and applicable to other similar features or aspects in anotherexemplary configuration of the disclosure. Accordingly, technicalfeatures described herein according to one exemplary configuration ofthe disclosure may be applicable to other exemplary configurations ofthe disclosure, and thus duplicative descriptions may be omitted herein.

Exemplary configurations of the disclosure will be described more fullybelow (e.g., with reference to the accompanying drawings). Likereference numerals may refer to like elements throughout thespecification and drawings.

FIG. 1 is a rear view of a sun visor assembly 100. FIG. 2A is a rearview of the sun visor assembly 100 with a connection arm releasablyconnected with a connection block. FIG. 2B is a rear view of the sunvisor assembly 100 with the connection arm disconnected from theconnection block.

Referring to FIGS. 1, 2A, and 2B, the sun visor assembly 100 includes asun visor panel 101. A first arm 102 extends from the sun visor panel101. An attachment assembly 110 is supported by the first arm 102. Thefirst arm 102 is rotatably coupled with the attachment assembly 110.Thus, the sun visor panel 101 may be rotated to a side of a motorvehicle to block sun through a side window of the motor vehicle. The sunvisor panel 101 may also be folded against a factory provided sun visorpanel (e.g., second sun visor panel 104) and folded against a ceiling ofa vehicle along with the factory provided sun visor panel 104. When thesun visor panel 101 and the factory provided sun visor panel 104 areboth deployed, two distinct sun visor panels are employed tosimultaneously block the sun through side and front windows,respectively, of a vehicle. The sun visor assembly 100 may be used as anafter market or add-on product, and is adapted to be connected with afactory installed sun visor panel that is generally only useful to blocksun through one of the front windshield or a side window of a motorvehicle.

The attachment assembly 110 is configured to detachably connect with asecond arm 103 of a second sun visor panel 104. The attachment assembly110 includes a connection block 111. The connection block 111 includesan orifice 112. A connection arm 113 includes a projection 114 at afirst end 121 of the connection arm 113. The projection 114 isconfigured to releasably connect with the orifice 112 of the connectionblock 111. A connection loop 115 extends from a second end 122 of theconnection arm 113. The connection loop 115 is configured to releasablyconnect with the second arm 103 of the second sun visor panel 104.

In an aspect of the present disclosure, the first arm 102 has a bentshape including a horizontal extending portion 131 and a verticalextending portion 132. The connection block 111 is supported by thevertical extending portion 132.

FIG. 3A is a rear view of the sun visor assembly 100 including a slidingextension panel 301 of the sun visor panel 101 in a retractedconfiguration. FIG. 3B is a rear view of the sun visor assembly 100 withthe sliding extension panel 301 in an extended configuration.

Referring to FIGS. 3A and 3B, the extension panel 301 is slidablyextendable from a distal end 302 of the sun visor panel 101 to extend alength of the sun visor panel 101. Thus, the sun visor panel 101 may beextended to various lengths to accommodate windows of various sizes, fordrivers of various sizes, and for various driving conditions in whichthe sun is positioned at different angles with respect to a vehicle.

FIG. 4A is a rear view of the sun visor assembly 100 including a foldingextension panel 401 of the sun visor panel 101 in a collapsedconfiguration. FIG. 4B is a rear view of the sun visor assembly 100including the folding extension panel 401 of the sun visor panel 101 ina deployed configuration.

Referring to FIGS. 4A and 4B, a hinge 403 connects the folding extensionpanel 401 to a distal end 402 of the sun visor panel 101. The hinge 403is configured to allow the folding extension panel 401 to fold away fromthe sun visor panel 101 to extend a length of the sun visor panel 401.Thus, the sun visor panel 101 may be extended to various lengths toaccommodate windows of various sizes, for drivers of various sizes, andfor various driving conditions in which the sun is positioned atdifferent angles with respect to a vehicle. The hinge 403 may be a butthinge, a mortise hinge, a continuous hinge, or a piano hinge.

FIG. 5A is a rear view of a horizontally translatable sun visor panel101 in a first horizontal position. FIG. 5B is a rear view of thehorizontally translatable sun visor panel 101 in a second horizontalposition that is aligned with the second sun visor panel 104.

Referring to FIGS. 5A and 5B, the sun visor panel 101 is horizontallytranslatable along the horizontal extending portion 132 of the first arm102. The horizontal extending portion 132 of the first arm 102 includesan extension portion 142 configured to allow horizontal translation ofthe sun visor panel 101. The extension portion 142 may be at leastpartially positioned between a front surface (not shown) and a rearsurface 105 of the sun visor panel. The vertical extending portion 131of the first arm 102 may also include a vertical extension portion 144at least partially extending within the connection block 111. Thevertical extension portion 144 allows vertical translation of the sunvisor panel 101 by vertically advancing the vertical extension portion144 within the connection block 111 and thereby vertically advancing thefirst arm 102 and the sun visor panel 101. Thus, the vertical andhorizontal positions of the sun visor panel 101 may be adjusted, asdesired, either when the sun visor panel 101 is in use, or when the sunvisor panel 101 is stowed away (e.g., when folded against a ceiling of amotorized vehicle along with the second sun visor panel 104). Asillustrated, e.g., in FIGS. 5A and 5B, the sun visor panel 101 we bevertically and/or horizontally aligned with and positioned in directcontact with the second sun visor panel 104, as desired (e.g., when thesecond sun visor panel 104 is in use, or when the second sun visor panel104 is folded against a ceiling of a motorized vehicle).

Referring again generally to FIGS. 1, 2A, and 2B, the projection 114 ofthe connection arm 113 releasably connects with the orifice 112 of theconnection block 111 by a snap-fit connection. A number of exemplarysnap-fit connections are described in more detail below with referenceto FIGS. 6 and 7.

FIG. 6 illustrates an exemplary cantilever snap joint 600 configured toreleasably connect the connection arm 613 with the connection block 611.

Referring to FIG. 6, the projection 614 of the connection arm 613 is anannular cantilever snap joint. The orifice 612 of the connection block611 is shaped and dimensioned to receive the annular cantilever snapjoint 614. In an aspect of the present disclosure, the projection 614 ofthe connection arm 613 is a discontinuous annular cantilever snap jointincluding a plurality of cantilever arms annularly spaced apart fromeach other. The orifice 612 of the connection block 611 is shaped anddimensioned to receive the discontinuous annular cantilever snap joint614.

FIG. 7 illustrates an exemplary ball and socket joint 700 configured toreleasably connect the connection arm 713 with the connection block 711.

Referring to FIG. 7, the projection 714 of the connection arm 713 isshaped as a ball. The orifice 712 of the connection block 711 is asocket shaped and dimensioned to releasably receive the ball 714.

FIG. 8 illustrates an exemplary connection loop 815 configured to becircumferentially coupled about the second arm 103 of a second sun visorpanel 104.

Referring to FIG. 8, the connection loop 815 is an adjustable ringconfigured to be circumferentially coupled about the second arm 103 ofthe second sun visor panel 104.

FIG. 9 illustrates an exemplary connection loop 915 coupled to a secondarm 903 of a second sun visor panel 904. Unless otherwise indicated, thesecond arm 103 is the substantially the same as the second arm 903, andthe second sun visor panel 104 is substantially the same as the secondsun visor panel 904.

Referring to FIG. 9, the adjustable ring 915 includes a rubber ring 951configured to directly contact the second arm 903 of the second sunvisor panel 904. An adjustable metal ring 952 is positioned around therubber ring 951. The adjustable metal ring 952 is configured to betightened around the rubber ring 951 to secure the adjustable ring 915to the second arm 903 of the second sun visor panel 904.

FIG. 10 is an interior view of a sun visor panel 1001 according toaspects of the present disclosure.

Referring to FIG. 10, the sun visor panel 1001 includes an inner layer1061 including plastic or a polymer, and an outer layer 1062 including afabric material covering the inner layer 1001.

In an aspect of the present disclosure, the first arm 102 includesmetal.

In an aspect of the present disclosure, the connection arm 113 and theprojection 114 are a single integrally formed structure.

In an aspect of the present disclosure, the connection block 111includes a plastic material or a polymer material.

FIG. 11 is a front, perspective view of a sun visor assembly 11100according to aspects of the present disclosure. FIG. 12 is an enlarged,perspective view of an attachment assembly 11110 of FIG. 11. FIG. 13 isrear view of the sun visor assembly 11100 of FIG. 11. FIG. 14 is anenlarged view of area A of FIG. 13.

Referring to FIGS. 11-14, the sun visor assembly 11100 includes a sunvisor panel 11101. A first arm 11102 extends from the sun visor panel11101. An attachment assembly 11110 is supported by the first arm 11102.The first arm 11102 is rotatably coupled with the attachment assembly11110. Thus, the sun visor panel 11101 may be rotated to a side of amotor vehicle to block sun through a side window of the motor vehicle.The sun visor panel 11101 may also be folded against a factory providedsun visor panel (e.g., second sun visor panel 104) and folded against aceiling of a vehicle along with the factory provided sun visor panel104. When the sun visor panel 11101 and the factory provided sun visorpanel 104 are both deployed, two distinct sun visor panels are employedto simultaneously block the sun through side and front windows,respectively, of a vehicle. The sun visor assembly 11100 may be used asan after market or add-on product, and is adapted to be connected with afactory installed sun visor panel that is generally only useful to blocksun through one of the front windshield or a side window of a motorvehicle.

The attachment assembly 11110 is configured to detachably connect with asecond arm 103 of a second sun visor panel 104. The attachment assembly11110 includes a connection block 11111. The connection block 11111includes an orifice 11112. A connection arm 11113 includes a projection11114 at a first end 11121 of the connection arm 11113. The projection11114 is configured to releasably connect with the orifice 11112 of theconnection block 11111 (e.g., by removably connecting a pin or screwinto orifice 12002 of connection block 11111 and into orifice 12003 ofthe projection 11114—see, e.g., FIG. 12). A connection loop 11115extends from a second end 11122 of the connection arm 11113. Theconnection loop 11115 is configured to releasably connect with thesecond arm 103 of the second sun visor panel 104.

In an aspect of the present disclosure, the second end 11122 ofconnection arm 11113 may be removably coupled with connection loop 11115by removably securing a pin or screw in orifice 12004 (see, e.g., FIG.12). Alternatively, the second end 11122 of connection arm 11113 may befixedly coupled with (e.g., welded to or integrally formed with)connection loop 11115.

Connection block 11111 may be removably coupled with arm 11102 byremovably securing a pin or screw in orifice 12005 (see, e.g., FIG. 12).

In an aspect of the present disclosure, the first arm 102 has a bentshape including a horizontal extending portion 131 and a verticalextending portion 132. The connection block 111 is supported by thevertical extending portion 132.

In an aspect of the present disclosure, the second end 11122 of theconnection arm 11113 is narrower in at least one direction than thefirst end 11121 of the connection arm 11112. For example, the second end11122 of the connection arm 11113 may define a tapered configuration. Inuse, this allows a factory installed sun visor to rotate freely withoutcontacting the second end 11122 of the connection arm 11113. Theconnection arm 11113 (e.g., at least the first end 11121 of theconnection arm 11113) may define an octagonal, hexagonal or squarecross-sectional shape along at least a portion of a length thereof,which is configured to mate with a corresponding shape of orifice 11112of connection block 11111. The second end 11122 of the connection arm11113 may have a different cross-sectional shape from a shape of thefirst end 11121 of the connection arm 11113. As an example, the firstend 11121 of the connection arm 11113 may define a semi-circular shapeor cylindrical shape.

In an aspect of the present disclosure, a magnet 11121 is supported onthe sun visor panel 11101. The magnet 11121 is configured tomagnetically secure the sun visor panel 11101 to an upper surface of avehicle. The magnet 11121 may be a single strip magnet, or a pluralityof individual magnets arranged in the sun visor panel 11101. As anexample, the magnet 11121 may be a neodymium magnet. The magnet 11121may be arranged on a single side of the sun visor panel 11101 or bothsides of the sun visor panel 11101 (e.g., to magnetically couple the sunvisor panel 11101 to factory sun visor panel 104.

The connection loop 11115 may include a hinge 12001 (see, e.g., FIG. 12)that allows the connection loop 11115 to open and close for attachmentwith an arm of a vehicle. The connection loop 11115 may be secured in aclosed position by removably attaching a pin our screw through aperture14001 (see, e.g., FIG. 14). As an example, orifice 12004 may be incommunication with aperture 14001.

As an example, the pins described herein may be cottar pins, split pinsor cotter keys.

As an example, each of the connection loop 11115 and connection arm11113 may be formed of or may include a metal such as steel or stainlesssteel.

It will be understood that various modifications may be made to theaspects and features disclosed herein. Therefore, the above descriptionshould not be construed as limiting, but merely as exemplifications ofvarious aspects and features. Those skilled in the art will envisionother modifications within the scope and spirit of the claims appendedthereto.

What is claimed is:
 1. A sun visor assembly, comprising: a sun visorpanel; a first arm extending from the sun visor panel; and an attachmentassembly supported by the first arm, the first arm rotatably coupledwith the attachment assembly, the attachment assembly configured todetachably connect with a second arm of a second sun visor panel, theattachment assembly including: a connection block defining an orificetherein; a connection arm including a projection at a first end of theconnection arm, the projection configured to releasably connect with theorifice of the connection block; and a connection loop extending from asecond end of the connection arm, the connection loop configured toconnect with the second arm of the second sun visor panel.
 2. The sunvisor assembly of claim 1, wherein the projection of the connection armreleasably connects with the orifice of the connection block by asnap-fit connection.
 3. The sun visor assembly of claim 1, wherein theprojection of the connection arm is an annular cantilever snap joint,and wherein the orifice of the connection block is shaped anddimensioned to receive the annular cantilever snap joint.
 4. The sunvisor assembly of claim 1, wherein the projection of the connection armis a discontinuous annular cantilever snap joint, and wherein theorifice of the connection block is shaped and dimensioned to receive thediscontinuous annular cantilever snap joint.
 5. The sun visor assemblyof claim 1, wherein the projection of the connection arm is shaped as aball, and wherein the orifice of the connection block is a socket shapedand dimensioned to releasably receive the ball.
 6. The sun visorassembly of claim 1, further including the first arm having a bentconfiguration including a horizontal extending portion and a verticalextending portion, wherein the connection block is supported by thevertical extending portion.
 7. The sun visor assembly of claim 1,wherein the sun visor panel is horizontally translatable along thehorizontal extending portion of the first arm.
 8. The sun visor assemblyof claim 7, wherein the horizontal extending portion of the first armincludes an extension portion configured to allow horizontal translationof the sun visor panel.
 9. The sun visor assembly of claim 8, whereinthe extension portion is at least partially positioned between a frontsurface and a rear surface of the sun visor panel.
 10. The sun visorassembly of claim 1, further including an extension panel, wherein theextension panel is slidably extendable from a distal end of the sunvisor panel to extend a length of the sun visor panel.
 11. The sun visorassembly of claim 1, further including an extension panel and a hingeconnecting the extension panel to a distal end of the sun visor panel,the hinge configured to allow the extension panel to fold away from thesun visor panel to extend a length of the sun visor panel.
 12. The sunvisor assembly of claim 11, wherein the hinge is a butt hinge, a mortisehinge, a continuous hinge, or a piano hinge.
 13. The sun visor assemblyof claim 1, wherein the connection loop is an adjustable ring configuredto be circumferentially coupled about the second arm of the second sunvisor panel.
 14. The sun visor assembly of claim 13, wherein theadjustable ring includes a rubber ring configured to directly contactthe second arm of the second sun visor panel, and an adjustable metalring positioned around the rubber ring, the adjustable metal ringconfigured to be tightened around the rubber ring to secure theadjustable ring to the second arm of the second sun visor panel.
 15. Thesun visor assembly of claim 1, wherein the sun visor panel includes aninner layer including plastic or a polymer, and an outer layer includinga fabric material covering the inner layer.
 16. The sun visor assemblyof claim 1, wherein the first arm includes metal.
 17. The sun visorassembly of claim 1, wherein the connection arm and the projection are asingle integrally formed structure.
 18. The sun visor assembly of claim1, wherein the connection block includes a plastic material or a polymermaterial.
 19. The sun visor assembly of claim 1, wherein the second endof the connection arm is narrower in at least one direction than thefirst end of the connection arm.
 20. The sun visor assembly of claim 1,further including at least one magnet supported on the sun visor panel,the at least one magnet configured to magnetically secure the sun visorpanel to an upper surface of a vehicle.